My HID Retro Fit

[Blurred Talon]

Figured I'd post this here to share some tech about my retrofitting OEM HID Projectors into DSM headlights.

I've got almost all the parts to start on my first ever retro fit. I've got some cool things planned for this.

Parts so far:
E55 Bi-Xenon Projectors
Bosch AL Gen 2 Ballasts
Osram Bulbs
OEM Talon Headlights

Pictures:

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

Oh, because I will be boosting the ballasts I need to keep them cool so, check this out.

You must be logged in to view this image or video.

Heat sink and fan.


I've decided to run FX-R projectors in the high beam spot. I'll be picking them up from The Retrofit Source.

You must be logged in to view this image or video.

I'll be using Phillips bulbs and 55w digital ballasts. Should be awesome

 

[Blurred Talon]

Cheap Talon headlights to be used for the retro.

You must be logged in to view this image or video.

Now for a bit of tech.
Opening Headlights With an Oven
Mechanics Gloves (to handle the lights)
Paint Scraper
Exacto Knife
Oven
Baking Sheet
Damp Towel

1. Grab your baking sheet and cover it with a damp towel. Wet things won't burn and you don't want to melt your headlight.
2. Remove the bulbs and metal clips from your headlights.
3. Place the head light on the baking sheet and put it all in the oven. Don't let the head light touch the sides of the oven.
4. Turn the oven to 210* and set the timer for 8 minutes.
5. Put on your Mechanics Gloves and wait.
6. When the timer goes off pull the light out and use the paint scraper to start prying the light apart. I use the scraper because it's flexable so it shouldn't break anything. Use the Exacto knife to cut the sealant. (Careful the sealant is some sticky shit!)
7. Your headlights are now apart.

You must be logged in to view this image or video.

Both headlights separated with all there pieces removed. I likely will not be putting the amber corners back in, remember I want to use LEDs. The lenses need to be cleaned up/restored and have the flutes removed, I'll likely do that tonight and maybe even paint the chrome bezels. Need to see what paint I have sitting around.

You must be logged in to view this image or video.

Also took some measurements since I had them all apart.
Low beam section:

You must be logged in to view this image or video.

You must be logged in to view this image or video.

High beam section:

You must be logged in to view this image or video.

You must be logged in to view this image or video.

The E55s will fit no problem in the low beam side. The FX-R in the high beams though, it's gonna be a TIGHT fit.

My E55 projectors left Cali at 1:15am yesterday, I should hopefully have them in another few days.

I started to sand and polish the lenses. Here's some shots of the sanding progress, I sanded the flutes out of the inside.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

I then started to polish them but I'm not pleased with the results yet. The flutes are still sort of visible and the my arms/hands are sore. I'm going to grab a Power Ball Mini and give that a shot. Should do a beater/quicker job then my hands. I might have to sand the inside more to get the flutes out.

Also painted the chrome shrouds flat black. This is after the first coat, too dark to get more pictures.

You must be logged in to view this image or video.

Here's the bezels after 3 coats of Duplicolor High Performance Wheel Coating . It was either this or manifold paint.

You must be logged in to view this image or video.

Should have both lenses cleaned and polished today and the bezels all painted.

 

[Boost92awd]

Looks good, cant wait to see the final outcome.

 

[HackZ]

So far its comming out really nice. You should consider using a heat sink from a laptop or Video card so you can keep the size down but still keep it cool.

 

[Blurred Talon]

I want the larger heat sinks because of the fact I'm boosting the ballasts.

Headlight bezels are painted, I'm working on cleaning/polishings the lenses.

 

[Blurred Talon]

It's been a good morning so far

You must be logged in to view this image or video.

Let see your PnP kit have a cut off like this!

You must be logged in to view this image or video.

Bright

You must be logged in to view this image or video.

 

[siceclipse]

Looks really good!

 

[97 GSX 97]

I've thought about doing this. I'll follow this, so please keep it updated.

 

[Hubbard 0]

I'm also planning on doing this. Please keep up the good work.

 

[Blurred Talon]

Thanks guys. I will keep this up to date as I go along. Maybe I'll even do a how to after I finish it all up.

Pulled the reflector bowls from the stock housing tonight.

You must be logged in to view this image or video.

I have most the mounting hardware, just need some brackets and it's time for the real fun to begin.

I've also played around with color modding the E55s. I've got more work to do with that but I'm pleased with the results so far.

 

[Blurred Talon]

I ARE FINISHED!!

You must be logged in to view this image or video.

Nah, I'm just kidding.
Projectors are ready for mounting in the passenger reflector bowl. Hopefully will have both mounted by the end of the weekend.

You must be logged in to view this image or video.

I had to cut LOTS out of the reflector bowl and notch the bottom for the Bi Xenon solenoid.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

Then I decided to play around with the power supply. Should look sweet

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

I still need to order some bezels for the projectors.
As for the projectors I want to mount in the high beam reflector bowl, I'm not sure about that. Found a local suppler which carries the FX-R projector so we're gonna meet up next week when I've got some free time and have a look to see if it will fit.

 

[Blurred Talon]

Thanks guys!!

Got some work done over the weekend.
Both reflector bowls are cut. I'll get the projectors mounted tomorrow morning. I need some more high heat black before the bowls get painted.

You must be logged in to view this image or video.

Cleaned up the headlight housings to I could paint them. High heat black inside, Hammered Grey outside.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

Worked on color modding the E55s too. Very pleased with results.
Stock

You must be logged in to view this image or video.

Color modded

You must be logged in to view this image or video.

You must be logged in to view this image or video.

That's it for now!

 

[97 GSX 97]

Are you good with lights or are you learning along the way? Also at the end if you don't mind get a running total for some of us so we know how much this will cost.

 

[Blurred Talon]

I'm a bit of an electrical nut so the electronics part of it is fun for me. This however is my first time doing a retrofit so I'm learning as I go along. Almost everything I've learned is from the forums at HID Retrofit Parts Projectors Ballasts D2S Bulbs. A huge wealth of knowledge over there, if you think what I'm doing is cool, you haven't seen nothing yet.

As for a running total, not really fair as I obtained my ballasts and bulbs via a trade. So that really cut the cost for me. I can guessimate though, ballasts $150-200, bulbs can be brought brand new for $80, my projectors were $110 shipped (all those prices were in USD). The spare talon headlights cost me $40CND. Plus factor in things like hardware, paint, sand paper, rubber compound, power ball mini, etc (I needed these you might not) let's say another $50. So that means I've spent $260 personally because I got the bulbs and ballasts for free.

However a good place for parts and even retrofit kits (not HID kits either, pre-packaged retro kits with bulbs, projectors, ballasts and shrouds) is The Retrofit Source - The Retrofit Source (U.S.) - HID Projector Retrofit Kits, Retrofit and HID Componenents, Projectors Lens, Wiring Harnesses, Shrouds and more!.
$390 gets you FX-R Bi-Xenon projectors, ballasts, bulbs and shrouds. Decent deal imo.

Also I'm adding a lot of extras that other people may not see a need for. Examples, flash to pass timer (leaves the lights on for 1 minute after flashing so they don't get abused), clear lenses for the E55s, shut down timer, the possibility of another set of projectors.
Once I'm finished I'll break down a price list on everything I've done personally. As stated I will likely post a how to also. For now though, another update!

Got 1 projector mounted today.

You must be logged in to view this image or video.

The lower screws are WAY too long. I need 1" screws and not 1.5". I'll try to get to the store to exchange the ones I have and then get the other projector mounted.
Almost in the home stretch.

 

[Jed_Atreides]

Never thought of using computer components that way. Interesting route.

 

[Highbooost]

This is the thread I have been waiting for for years, a proper step by step to doing HID correctly, and what this has shown me is that this is wayyyy to much work. I bought some Silverstar Ultras the other day which are 4100K and even if I would have done HID I would have only done 4500 or 5000k anyhows, mine was easier and cheaper and made for my headlights, but none the less continue with the project I was just giving an alternative. Who knows maybe some day I'll still do the HIDs. Thumbs up on the project thanks for doing it.

Later Dr Turbo

 

[Hubbard 0]

This is the thread I have been waiting for for years, a proper step by step to doing HID correctly, and what this has shown me is that this is wayyyy to much work. I bought some Silverstar Ultras the other day which are 4100K and even if I would have done HID I would have only done 4500 or 5000k anyhows, mine was easier and cheaper and made for my headlights, but none the less continue with the project I was just giving an alternative. Who knows maybe some day I'll still do the HIDs. Thumbs up on the project thanks for doing it.

Later Dr Turbo

Your silverstar bulbs are like a candle compared to a proper retrofit. There is more to it then just color range, buddy.

 

[snowborder714]

Which boosting method are you using? I've seen two (that I know of) on HID Planet.
Which clear lenses are you using? ZKW replicas?
What have you been doing to color mod the E55's?
I don't believe I've read about the flash to pass timer. Have people had issues with playing with flash to pass too much?
How does the shut down timer work?

Happen to have any links to this stuff you're doing on HID Planet? I'll definitely do some searching myself, but just curious if you have them off hand.

 

[Blurred Talon]

This is the thread I have been waiting for for years, a proper step by step to doing HID correctly, and what this has shown me is that this is wayyyy to much work. I bought some Silverstar Ultras the other day which are 4100K and even if I would have done HID I would have only done 4500 or 5000k anyhows, mine was easier and cheaper and made for my headlights, but none the less continue with the project I was just giving an alternative. Who knows maybe some day I'll still do the HIDs. Thumbs up on the project thanks for doing it.

Later Dr Turbo

Your silverstar bulbs are like a candle compared to a proper retrofit. There is more to it then just color range, buddy.

Yea no kidding.
Though imo, Silverstars are the best Halogen bulb.
You might consider it a lot of work but I consider it fun

Which boosting method are you using? I've seen two (that I know of) on HID Planet.
Which clear lenses are you using? ZKW replicas?
What have you been doing to color mod the E55's?
I don't believe I've read about the flash to pass timer. Have people had issues with playing with flash to pass too much?
How does the shut down timer work?

Happen to have any links to this stuff you're doing on HID Planet? I'll definitely do some searching myself, but just curious if you have them off hand.

My clear lenses are ZKW replicas from The Retrofit Source.
The boosting method I will eventually use can be found in this link: HiDPlanet.com :: Log in
Here's the info about color modding the E55s: HiDPlanet.com :: Log in

As for the flash to pass, well, constantly started and turning off the HID bulbs will shorten their life span. So I rather spend the cash to buy the timer and just be safe. I know I've read about it on HID Planet but no links.

The shut down timer is basically like on some luxury cars. When the car and lights are turned off, the stay on for a minute or so so you can walk into the house or whatever.

 

[Hubbard 0]

I eventually plan to do this too. I'm just too deep in other overly ambitious projects right now. This will be a great reference though.

 

[snowborder714]

Good to hear you're going with the replicas. I've read really good things about them, so it'd be nice to hear what you think about them when you're done.

Thanks for the links! Did you check out azdave's mod? Or was the one you chose just easier and less time consuming?

Are both the timers (flash to pass and shutdown) something you just buy and wire in?

 

[Blurred Talon]

I'll be doing Dave's stutter shutter eventually, just a matter of time. Right now I want to get the lights on for a big meet that is coming up. After that it's only a matter of wiring.

Yea, you just wire them in and set them up. I'll provide part numbers tomorrow.

 

[Blurred Talon]

The timer part number is ELK-960.
First post on this page talks about wiring it, 3/4 of the way through the post.
HiDPlanet.com :: Log in

 

[Blurred Talon]

Good to hear you're going with the replicas. I've read really good things about them, so it'd be nice to hear what you think about them when you're done.

Thanks for the links! Did you check out azdave's mod? Or was the one you chose just easier and less time consuming?

Are both the timers (flash to pass and shutdown) something you just buy and wire in?

Got the FX-R projectors from Ken at Xenmod.ca today. Must say I am very pleased with them so far. Test fired them tonight and WOW, awesome cut off.
Fitting them in my high beam bowl on the other hand, challenge.

Need to get some bulbs and ballasts for them, gonna be sweet once this is finished.

I have pictures but no lap top to upload them. My computer is in the shop. I will keep working and update once I'm running again.

 

[Blurred Talon]

Well ####, these FX-R projectors are pretty honking big. I trimmed one reflector bowl, kinda widged the FX-R in there. Mounted the bowl back in the head light and SNAP! Broke the bowl, FML.

So I have to go to Crappy Tire anyhow, I'll get some JB Weld (not the shit JB Weld Quick I have right now, stuff is pure crap. Original JB Weld FTW!) and try to save this reflector bowl. Finding a single headlight will be a bit of a pain so I'm going to try and save this one.

Looks like I will have shave the FX-R projectors on the sides to get them to fit. I could even cut some off the top of them but I rather not if it's at all possible. Right now the entire bottom and back of my high beam reflector bowl is gone. I'm going to try and get these things to fit with some grinding of the sides. Worse case, I will have to cut the lip off the top.

Oh, my lap top is in transit back to me so I should have pictures by the end of the weekend I hope.